Easy lift spreader beam rack

ABSTRACT

In the counter-top fabrication business, the most serious problem is the movement of the material because it is so heavy. The racks used to transport pieces are normally 4 to 8 inches tall off the ground which is just enough room for the forks of a forklift to raise the rack. Therefore, installers must squat all the way to the ground to lift the pieces. The invention we created is an easy lift rack raising the height of the countertop material as high as possible while still being able to travel safe. We have lifted the rack as high as possible to reach what OSHA calls the “power zone” for lifting. This rack itself can be picked up with a forklift from the spreader beam attached to the top. Our rack can easily be moved around with a forklift, and allows for safe and easy loading/unloading of countertop material.

BACKGROUND

In the counter top fabrication business, the biggest and most seriousproblem is the movement of material. Material must be moved from slabracks to machines for fabrication, then onto a delivery vehicle to bebrought to the end user's location and lastly, removed from the vehicleto be installed. The biggest reason for concern is that kitchencountertop pieces, on average, weigh 200 to 400 pounds while islands canweigh up to 1200 pounds. The racks used to transport pieces are normally4 to 8 inches tall off the ground which is just enough room for theforks of a forklift to raise the rack. Therefore, installers must squatall the way to the ground to lift the pieces. We have been in thecountertop fabrication business for the last ten years. Moving thismaterial is a challenge in two ways: we must figure out how to move thematerial without causing injuries to employees, but also how to do itwithout breaking or damaging the material. The granite material comes inslabs that are 72 inches by 120 inches, and can weight up to 1200pounds. Even after the slab is cut up into pieces, it can still weighanywhere from 200 to 1200 pounds. After we receive the 1200-poundgranite slabs from wholesalers, the next step is to lay it down on a sawto cut. A special boom on the forklift is made to handle that muchweight. The slabs can be laid over with tension straps, or with asuction hoist hanging form the forklift crane. The last and least safeway to do this would be four men laying the slab down on the saw withtheir hands. Once the slab has been cut up on the saw, the pieces arethen ready to move to the CNC, profiler, or work tables. The finishedpieces are now loaded onto the rack on the truck or trailer or an easylift rack in the shop. The rack can be loaded in the shop and the fullyloaded rack can be moved to the trailer with the forklift making it aquick, safe, and easy process. Lastly, the pieces must be taken off therack and into a home or business to be installed. Our rack deals withthe last step in this process, making it quicker and much safer to moveand remove pieces off the rack.

BRIEF SUMMARY OF THE INVENTION

The invention we created is an easy lift spreader beam rack engineeredfor a safe maximum of 5000 pounds. We have invented a rack that raisesthe height of the countertop material as high as possible on the rackwhile still being able to travel safe. It raises the rack from 2 to 18inches based on the end user's needs. We are lifting the rack as high aspossible to get reach what OSHA calls the “power zone” for lifting.While the racks are customized to end user's needs, we want the liftingpoint as high as possible while keeping the top of rack low enough toensure safe transportation. On top of not having to squat all the waydown to pick up the material, there are additional benefits to raisingthe rack. If raised properly, the rack can be moved with a forklift andplaced on a trailer, including those with 12-inch side rails. It alsoallows drop down pins in each of the four corners that go through holeson the trailer providing an extra degree of safety during transport.Lastly, when the rack is moved from the trailer back to the shop, wheelscan quickly be installed by removing the extension pins. The standardracks in the countertop industry are 4 to 6 inches off the ground,designed just high enough so that the forks on a forklift can pick itup. This does not consider the person squatting down to 6 inches to lift200 to 1200-pound pieces; our racks are designed to do just that. Wehave many heights and six different designs to accomplish this inaccordance of the installer's needs. There are three considerations whendealing with this. First, we must decide which height will make the bestpossible outcome; the ideal height for the installer maximizes his“power zone.” Second, we must be low enough for installers attach strapsto the top of the rack, securing the pieces. The average job has 5 to 15different pieces. When one piece is moved off the rack to be installed,the straps must be reset to keep the pieces secure. Lastly, the heightof the rack must allow clearance for the side rails on the trailer.Since the standard utility trailer has 12-inch side rails, the rackwould need to also be 12 inches tall. At 12 inches, the material is 18inches off the ground verses 6 inches, moving it into the “power zone.”This will also allow the rack to clear the side rails and fenders on atrailer ensuring that it can be loaded and unloaded properly. At thisheight, you will still be able to reach the safety straps as needed.Depending on user preference, the racks can be secured together threedifferent ways: Nuts and bolts, U-bolts, or welded together.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1. Side end-angle view of lift rack

FIG. 2. End view of lift rack

FIG. 3. Side view of lift rack

FIG. 4. Top view of lift rack

FIG. 1.

-   -   1) Location where countertop is stacked on rack    -   2) Base-upright which determines the final height of countertop        material off the floor    -   3) Side forklift-mount    -   4) Fold-down step    -   5) End forklift-mount    -   6) Top upright of upper section of rack    -   7) Top hooks where mounting straps are attached    -   8) Corner tubing mounted to install drop-down legs during        transportation or installing wheel assembly    -   9) Lower platform support    -   10) Large ring used to hook cable to raise rack    -   11) Heavy duty spreader beam used to displace weight when picked        up from the top

FIG. 2.

-   -   1) Location where countertop is stacked on rack    -   2) Base-upright which determines the final height of countertop        material off the floor    -   3) Lower platform base of end rack    -   4) Fold-down step    -   5) End forklift-mount    -   6) Top upright of upper section of rack    -   7) Large ring used to hook cable to raise rack    -   8) Heavy duty spreader beam used to displace weight when picked        up from the top    -   9) Corner tubing mounted to install drop-down legs during        transportation or installing wheel assembly

FIG. 3.

-   -   1) Location where countertop is stacked on rack    -   2) Base-upright which determines the final height of countertop        material off the floor    -   3) Side forklift-mount    -   4) Fold-down step    -   5) Corner tubing mounted to install drop-down legs during        transportation or installing wheel assembly    -   6) Top upright of upper section of rack    -   7) Top hooks where mounting straps are attached    -   8) Heavy duty spreader beam used to displace weight when picked        up from the top    -   9) Large ring used to hook cable to raise rack    -   10) Lower platform base

FIG. 4.

-   -   1) Location where countertop is stacked on rack    -   2) Top hooks where mounting straps are attached    -   3) Lower platform base    -   4) Fold-down step    -   5) Large ring used to hook cable to raise rack    -   6) Heavy duty spreader beam used to displace weight when picked        up from the top

1. A Easy Lift Rack, comprised: metal supports bolted and or weldedtogether to lift rack off the ground to loading level in order to reachwhat OSHA calls the “power zone” for safe lifting.
 2. A Easy Lift Rackin #1 further comprised: by the metal support in a mounted in a verticalposition, thus raising height of platform of rack to a safe loading andunloading position.
 3. A Easy Lift Rack in #1, further comprised: ofsleeves in each corner to mount safety stops for use on trailers andwheels for use off-trailer.
 4. A Easy Lift Rack in #1, furthercomprised: of a spreader beam built into the top of the rack allowingthe loaded rack (up to 10,000 lbs) to be picked up by the two largerhooks on top of the beam for loading and unloading rack.
 5. A Easy LiftRack, comprised: of metal supports bolted and or welded together toraise racks high enough to clear side rails of trailer.
 6. A Easy LiftRack in claim #5, comprised: of lift points for forklift to raise racksabove side rails on trailers for safe and quick loading and unloading.